EP0909635B1 - Produit stratifié décoratif à base de poly(fluorore de vinylidène) - Google Patents
Produit stratifié décoratif à base de poly(fluorore de vinylidène) Download PDFInfo
- Publication number
- EP0909635B1 EP0909635B1 EP19980203000 EP98203000A EP0909635B1 EP 0909635 B1 EP0909635 B1 EP 0909635B1 EP 19980203000 EP19980203000 EP 19980203000 EP 98203000 A EP98203000 A EP 98203000A EP 0909635 B1 EP0909635 B1 EP 0909635B1
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- European Patent Office
- Prior art keywords
- layer
- laminate
- adhesive
- decorative
- printed
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- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Revoked
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
- B32B15/082—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising vinyl resins; comprising acrylic resins
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
- B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2311/00—Metals, their alloys or their compounds
- B32B2311/24—Aluminium
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2605/00—Vehicles
- B32B2605/003—Interior finishings
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2605/00—Vehicles
- B32B2605/18—Aircraft
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
- Y10T428/24612—Composite web or sheet
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24628—Nonplanar uniform thickness material
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/3154—Of fluorinated addition polymer from unsaturated monomers
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31678—Of metal
- Y10T428/31692—Next to addition polymer from unsaturated monomers
- Y10T428/31699—Ester, halide or nitrile of addition polymer
Definitions
- the present invention generally relates to a decorative laminate and, more particularly, to a polyvinylidene fluoride-based decorative laminate.
- Preferred decorative laminates have exterior surfaces that are textured and exhibit surface relief.
- Decorated interior panels are typically formed by heating and then stretching a plastic decorative laminate onto the panel. While textured panels generally retain their surface relief when formed onto smooth and relatively simple contoured panels, significant loss of texture occurs for conventional plastic laminates when they are formed onto compound contoured panels, or when they are formed at higher temperatures and/or under vacuum.
- Textured decorative laminates generally include at least two layers; a first embossed layer that imparts surface relief to the laminate and a second decorative layer that overlies the first.
- the decorative layer is typically either screen printed (i.e., multigraphics) or integrally colored (i.e., internally pigmented).
- a laminate construction having a first embossed layer and a second decorative layer is commonly referred to as a single decorative laminate.
- the single laminate includes a textured layer consisting of a thermosetting emboss resin (e.g., a 3 mil thick layer of a polyurethane-phenoxy emboss resin) overlaid with a decorative layer composed of a thin layer of pigmented thermoplastic film (e.g., a polyvinyl fluoride film, such as Tedlar®, having a thickness of about 50 ⁇ m (2 mil).
- a thermosetting emboss resin e.g., a 3 mil thick layer of a polyurethane-phenoxy emboss resin
- a decorative layer composed of a thin layer of pigmented thermoplastic film (e.g., a polyvinyl fluoride film, such as Tedlar®, having a thickness of about 50 ⁇ m (2 mil).
- a second decorative laminate commonly referred to as a double decorative laminate, is a laminate construction that includes, in addition to an embossed layer and a decorative layer, a structural layer (e.g., a thermoplastic resinous layer).
- a typical double decorative laminate includes two thermoplastic layers, an outer decorative layer and an inner structural layer, with an emboss resin layer positioned in between.
- These decorative laminates are generally prepared by collating sheets of the component plastic materials followed by simultaneously laminating and embossing in a hot press process.
- thermosetting emboss resin is "molded" by the texture media (i.e., the textured press).
- the emboss resin is said to be molded because shear flow occurs within the thermosetting resinous material resulting in the layer's cross-sectional thickness variation, i.e., the creation of an embossed or textured surface.
- the hot press also "forms" the decorative layer.
- the decorative thermoplastic layer or film is said to be formed because its viscosity is too high for shear flow to occur, and thus cannot be molded and, although the film does stretch during forming onto the textured layer, the decorative film remains relatively uniform in thickness.
- the heat and length of the hot press cycle result in emboss resin curing or crosslinking, which effectively raises the emboss layer's viscosity and counteracts the residual stresses of the thermoplastic film layer during forming.
- the crosslinked emboss resin provides for texture retention in subsequent application processes in which the decorative laminate is heated and vacuum formed onto composite panels.
- texture inversion can occur as a result of the relatively greater elastic modulus of the decorative thermoplastic layer compared to the textured thermosetting emboss layer.
- thermoset resin-containing decorative laminate constructions described above suffer from several disadvantages including loss of texture retention when the laminate in heated and formed onto a composite panel.
- single decorative laminates perform poorly when they are elongated more than about 5%, and double decorative laminates begin to lose texture at about 10% elongation.
- thermosetting emboss resin because of the presence of the thermosetting emboss resin, these decorative laminates can only be practically produced in press processes, which are economically disadvantageous for the production of large quantities of laminate.
- the emboss resin is a thermosetting resin
- sufficient time e.g., from 15 to 30 minutes
- a specific cure or thermoset temperature e.g., 140°C (285°F)
- a specific cure or thermoset temperature e.g. 140°C (285°F)
- cure i.e., crosslink
- Single decorative laminates are generally difficult to roll process because of the misbalance of the elastic modulus of the thermosetting emboss resin and the thermoplastic layer.
- the surface of pigmented polyvinyl fluoride a common decorative layer, is disrupted by pigment particles that protrude from the material's surface. Because these particles are generally inorganic oxides, the particles are harder than most materials, including metals, that contact the surface.
- metal objects e.g., jewelry, buckles, coins
- metal is ablated and left on the surface as a dark streak. This phenomena is commonly referred to as "coining.”
- These metallic streaks are difficult to clean because the residual metals are typically not affected by cleaners ordinarily used for cleaning plastic surfaces, and therefore must be abraded from the decorative surface.
- the pigment particles may also absorb or adsorb other chemicals leaving stains that are also difficult to clean. While it may be possible to force the particles back into the polymer matrix during embossing with heat and pressure, the relatively inelastic nature of the polyvinyl fluoride material requires relatively harsh conditions.
- the present invention seeks to provide a decorative laminate that overcomes the difficulties noted above, and provides a decorative laminate that is characterized as having high texture retention when stretched or formed on a composite panel, is readily formed by economical processes, and yet is soft enough so as not to suffer from disadvantageous surface properties.
- the decorative laminate formed in accordance with the present invention is a flexible, organic polymer-based laminate that overcomes the disadvantages of conventional laminates that include thermosetting emboss resins for imparting texture to the laminate.
- the flexible laminate formed in accordance with the present invention includes a polyvinylidene fluoride-based material that serves to receive and retain texture or surface relief, and also to impart further decorative features to the laminate.
- the polyvinylidene fluoride layer is moldable in the press process, has no memory, and eliminates the necessity of the thermosetting emboss resin present in conventional laminates. By replacing the thermosetting emboss resin, laminate forming processes generally have shorter press cycles, which results in significant cost savings. Because the polyvinylidene fluoride layer is a thermoplastic, in contrast to the thermosetting emboss resin, the laminate can be continuously roll embossed in processes that provide further savings in labor costs and decorative laminate wastes in vacuum forming. In addition, a reduction in laminate weight, a critical factor in aircraft component considerations, is also achieved.
- the laminate's texture does not invert under the tension of vacuum forming and provides for high texture retention even for greatly stretched or elongated parts.
- the polyvinylidene fluoride material is relatively soft, pigmented polyvinylidene fluoride materials offer the advantage that the pigment particles can be pushed below the surface of the polymer layer or capped with a clear layer, thus eliminating the coining problem.
- the flexible, organic polymer-based laminate formed in accordance with the present invention generally includes a structural or backing layer made from a thermoplastic material and a textured layer composed of a polyvinylidene fluoride-based material.
- the laminate's textured layer is affixed to the structural layer by an intermediate layer that includes an adhesive material.
- the laminate of the present invention includes a metal foil layer positioned between the structural and textured layers.
- the metal foil is an aluminum foil.
- the laminate of the present invention may further include an adhesive layer for affixing the laminate to a substrate.
- the adhesive layer is a heat-activatable or pressure-sensitive adhesive layer.
- the laminates of the present invention can also include a printed layer that overlies the textured layer.
- the present invention is generally directed to a decorative laminate and, more particularly, to a flexible, organic polymer-based decorative laminate.
- the decorative laminate formed in accordance with the present invention can be formed onto a composite panel with the retention of texture to provide a decorative panel.
- the decorative panel is particularly well suited as a component for commercial aircraft interiors.
- the laminate formed in accordance with the present invention includes a textured layer attached to a structural layer through a layer that contains an adhesive material.
- the textured layer includes an outer textured surface.
- the laminate possesses the advantageous property of texture retention, which enables the laminate to be formed onto a composite panel to provide a textured, decorative panel without substantial loss of the laminate's surface relief.
- Decorative laminates are known in the art and representative laminates are illustrated in FIGURE 1.
- single decorative laminate 10 includes decorative layer 12 that overlies emboss layer 14.
- a double decorative laminate 20 having structural layer 16, in addition to decorative layer 12 and emboss layer 14 is illustrated in FIGURE 1B.
- Emboss layer 14 is composed of a thermosetting resin, for example, a polyurethane-phenoxy emboss resin, which is molded by the texture media in the hot press cycle during the laminate's construction. Through the application of heat and pressure by the hot press, the thermosetting resin is cured and takes on the texture or surface relief of the texture media (i.e., the texture of the press face plate).
- decorative layer 12 which is composed of a thermoplastic resinous material, is formed by the texture media and remains substantially uniform in thickness.
- the decorative laminates described above retain their texture when applied to flat or simple contoured panels and formed at fairly low temperatures and requiring little, if any, forming or stretching.
- application of these laminates to compound contour panels generally requires higher forming temperatures, which results in considerable laminate stretching or elongation.
- the laminate formed in accordance with the present invention does not include a thermosetting resinous plastic to provide texture to the laminate.
- the decorative laminate of this invention includes a polyvinylidene fluoride-based layer that serves to receive and retain texture and further serves as a decorative layer that can be pigmented and/or receive printed graphics.
- Conventional decorative laminates accomplish the dual function of texture and decor through a dual-layer construction; namely, a first thermosetting embossable resinous layer for receiving laminate texture and a second thermoplastic decorative layer for receiving printed graphics and/or for imparting color to the laminate.
- the laminate of the present invention is a flexible, organic polymer-based laminate that retains texture when heated and formed onto composite panels.
- the laminate is primarily composed of organic polymeric materials and, because of safety considerations associated with commercial aircraft, a primary utility of the decorative laminates of this invention, the organic polymers are preferably flame resistant fluorinated organic polymers.
- representative decorative laminate 30 includes a textured layer 32 having a textured outer surface, indicated by the wavy line in the figure, structural layer.34, and layer 36 that contains an adhesive material, positioned between layers 32 and 34, that affixes the textured layer to the structural layer.
- Textured layer 32 is composed of a melt processable, thermoplastic material that has no memory such that, when the material is exposed to heat and a texture media, the layer adopts texture imparted by the texture media, which is retained on cooling.
- the textured layer includes, as a principal component, a thermoplastic fluorinated organic polymer.
- the fluorinated polymer is a fluorocarbon such as a polyvinylidene fluoride-based material.
- polyvinylidene fluoride-based material refers to a thermoplastic polymeric material that is capable of texture retention and includes a polyvinylidene fluoride polymer (i.e., a polymer formed from vinylidene fluoride).
- the fluorinated polymer is generally a polymer, copolymer, or terpolymer of vinylidene fluoride.
- the thermoplastic fluorocarbon is the polyvinylidene fluoride (PVDF) commercially available under the designation Kynar®, a trademark of Elf Atochem.
- the textured layer can also include acrylic, polyurethane, flame retardants, and pigments.
- the textured layer includes an organic polymer that is melt processable below about 171°C (340°F), and more preferably at about 160°C (320°F).
- PVDF is melt-processable from 150°C (300°F) to 315°C (600°F)
- PVDF-based layers can be readily embossed in a press process at 160°C (320°F).
- Suitable PVDF-based materials include PVDF polymer films having thicknesses ranging from about 25 ⁇ m (1 mil) to about 130 ⁇ m (5 mil).
- the PVDF-based material is 60 ⁇ m (2.5 mil) thick Avimark Kynar® film commercially available from Avery Dennison (Schererville, IN).
- the textured PVDF-based layer can be clear and colorless or, alternatively; can be colored and include pigmented particles. Because of the melt processable nature of PVDF, pigmented particles contained within a PVDF-based layer can be readily pushed below the surface of the textured layer during the press processing, thereby eliminating any coining problem. The coining problem can also be eliminated by capping the pigmented layer with a thin colorless layer.
- the decorative laminate formed in accordance with the present invention includes a structural layer composed of a thermoplastic material.
- the thermoplastic material includes a thermoplastic fluorinated organic polymer, preferably a fluorocarbon such as polyvinyl fluoride (PVF) or PVDF.
- the fluorocarbon is a polyvinyl fluoride-based material.
- polyvinyl fluoride-based material refers to a polyvinyl fluoride polymer (i.e., a polymer formed from vinyl fluoride).
- the fluorinated polymer is generally a polymer, copolymer, or terpolymer of vinyl fluoride.
- thermoplastic fluorocarbon useful in the structural layer is the polyvinyl fluoride commercially available under the designation Tedlar®, a trademark of E.I. DuPont de Nemours & Co., Wilmington, DE.
- the structural layer is a 50 ⁇ m (2.0 mil) thick TEB20BE5 Tedlar® film.
- a layer containing an adhesive material affixes the textured layer to the structural layer.
- textured layer 32 is affixed to structural layer 34 by adhesive material-containing layer 36.
- Layer 36 can include any adhesive material suitable for affixing the textured layer to the structural layer.
- Suitable adhesive materials include thermoplastic and thermosetting adhesive materials such as acrylic and polyurethane adhesive materials.
- the adhesive material is an acrylic adhesive having a thickness of about 5 ⁇ m (0.2 mils), commercially available from DuPont under the designation 68080 or 68040 acrylic adhesive.
- the decorative laminates of the present invention include printed laminate constructions.
- a representative printed laminate of the present invention is illustrated in FIGURE 3.
- printed laminate 40 includes, in addition to textured layer 32, structural layer 34, and adhesive-containing layer 36, printed layer 42 and capping layer 44.
- Printed layer 42 can include ink or toner that is deposited on textured layer 32 by screen, electrostatic transfer, ink jet, and gravure processes, among others.
- Capping layer 44 provides protection to the ink layer, and preferably requires no adhesive for bonding to the printed laminate.
- Preferred capping layers include thermoplastic fluorinated polymer films such as PVF and PVDF films.
- the capping layer preferably has a thickness from about 10 ⁇ m (0.4 mil) to about 25 ⁇ m (1.0 mil) and is made of clear PVDF film such as is commercially available from Avery Dennison under the designations Avimark C40 and C70.
- the decorative laminates of this invention are formed onto composite panels that are useful in commercial aircraft interiors.
- the laminate formed in accordance with the present invention includes an adhesive layer for affixing the laminate to a substrate, such as a structural panel of an aircraft interior.
- a representative laminate formed in accordance with the present invention and having an adhesive layer is illustrated in FIGURE 4.
- decorative laminate 50 includes, in addition to textured layer 32, structural layer 34, and adhesive-containing layer 36, adhesive layer 38 adjacent structural layer 36 for affixing laminate 50 to a substrate.
- Suitable adhesive layers include pressure-sensitive and heat-activatable adhesive layers.
- the pressure-sensitive adhesive layer can be preapplied to the laminate as a film or coating.
- Suitable pressure-sensitive adhesives include, for example, a 76-152 ⁇ m (3-6 mil) thick adhesive available from the 3M Company (Knoxville, IA) under the designation 468MPF.
- the pressure-sensitive adhesive is a 76 ⁇ m (3 mil) thick adhesive available from Bostik Inc. (Middleton, MA) under the designation S408-4084.
- the decorative laminate can be applied to a substrate by a heat-activatable adhesive.
- Preferred heat-activated adhesives include thermosetting and thermoplastic adhesives. Thermosetting adhesives can be combined with a solvent and applied to the panel by spraying. The laminate can then be affixed to the panel by vacuum-forming the laminate onto the panel, followed by heating to cure the adhesive and fix the laminate to the panel.
- the heat-activatable adhesive is a thermoplastic adhesive, which can be applied to a structural panel by heating and which, for repair or refurbishment, can also be stripped from the panel by heating.
- a preferred reversibly affixable heat-activatable adhesive is a 38 ⁇ m (1.5 mil) thick film available from Bostik under the designation 10-309-1.5.
- the heat-activatable adhesive can be hot laminated to structural layer 34 to provide adhesive layer 38 as indicated in FIGURE 4.
- Printed decorative laminate 40 can also include an adhesive layer 38 for affixing the laminate to a substrate or structural panel.
- a representative printed decorative laminate having an adhesive layer for affixing the laminate to a substrate is indicated by reference numeral 60 in FIGURE 5.
- the flexible, decorative laminates of the present invention can be formed by collating the materials described above and then simultaneously laminating and embossing (i.e., imparting texture thereto) in a hot press process.
- the laminates of this invention can be formed by a thermoplastic embossing process as described by Pasquale in Web Processing and Converting Technology and Equipment, Van Nostrand Reinhold, Inc., 1984.
- the decorative laminate of the present invention retains its texture when stretched. Generally, the laminate retains at least about 70%, preferably about 80%, of its texture when its area is increased by stretching by at least about 10%.
- a method for determining texture retention is described in Example 1. Texture retention performance of a representative decorative laminate formed in accordance with the present invention is compared to a conventional laminate in Example 1. The texture retention of the representative PVDF-based decorative laminate was determined to be significantly greater than for a conventional laminate. Increasing the area of the laminate by 25% resulted in a texture retention value of 80% for the PVDF-based laminate, while the conventional laminate lost about half of its texture when similarly stretched.
- the PVDF-based laminate was found to be more formable than the conventional laminate, which could not be stretched to increase its area by 30% in a vacuum forming operation. Presumably the laminate could stretch more, but under the same pressure (about 0.8 atmosphere), the PVDF laminate forms more. Accordingly, these results demonstrate that PVDF-based laminates are well suited for forming onto compound contoured panels while at the same time retaining their surface texture.
- the flexible, decorative laminate formed in accordance with the present invention can also include a metal foil layer.
- the metal foil layer is incorporated into the laminate at least in part to retard heat release from the laminate in the event of laminate combustion.
- the metal foil is an aluminum foil.
- laminate 70 includes textured layer 32, structural layer 34, metal foil layer 72, and adhesive-containing layers 36.
- Metal foil layer 72 is positioned between textured layer 32 and structural layer 34 and affixed to these layers by adhesive-containing layers 36.
- the laminates of the present invention that include metal foil layers can also include printed layers and/or adhesive layers for affixing the laminate to a substrate or structural panel.
- printed laminate 80 includes textured layer 32, structural layer 34, metal foil layer 72, adhesive-containing layers 36, printed layer 42, and capping layer 44.
- decorative laminate 90 includes textured layer 32, structural layer 34, metal foil layer 72, adhesive-containing layers 36, and adhesive layer 38 for affixing the decorative laminate to a substrate.
- Decorative laminate 100 illustrated in FIGURE 9 combines the features of laminates 80 and 90 and provides a printed decorative laminate that includes a metal foil and that further has an adhesive layer for affixing the laminate to a substrate.
- Another advantage of the decorative laminate of the present invention relates to its relatively low weight compared to conventional laminates containing thermoset resins. As indicated in Table 2 in Example 2 below, a representative decorative laminate formed in accordance with the present invention weighs about 33% less than a similar conventional laminate. Such a weight difference is the realization of a significant economic advantage for commercial aircraft that include such laminates.
- the decorative laminate is composed primarily of fluorinated organic polymers, which are, in general, flame resistant.
- embodiments of the laminate that include a metal foil layer have retarded heat release compared to laminates that lack such a foil layer.
- the Federal Aviation Administration (FAA) has required that materials used in aircraft interior construction pass certain flammability, heat release, and smoke emission tests. See Title 14 of the Code of Federal Regulations, Part 25, Appendix F, Part I: Test Criteria and Procedures; Part IV: Test Method to Determine Heat Release Rate; and Part V: Test Method to Determine Smoke Emission.
- the texture retention performance of a representative decorative laminate formed in accordance with the present invention is compared to a conventional decorative laminate.
- the PVDF-based laminate tested was composed of a PVDF-based textured layer (Kynar®) affixed to a PVF-based structural layer (Tedlar®) with an acrylic adhesive (DuPont 68080).
- the conventional laminate was composed of a pigmented PVF-based (Tedlar®) decorative layer bonded to a textured emboss resin layer (polyurethane-phenoxy resin, Bostik 10-669-3) overlying a pigmented PVF-based (Tedlar®) structural layer.
- each laminate sample was omnidirectionally stretched at 150°C (300°F) to increase the laminate's area by 15, 20, 25, and 35%, respectively.
- Rz average maximum peak to valley height
- Texture retention was determined by dividing the average maximum peak to valley height by the maximum peak to valley height in the unstretched laminate and then multiplying by 100%. The results are tabulated in Table 1 below.
- PVDF-based laminate tested was composed of a printed PVDF-based textured layer (Kynar®) affixed to a PVF-based structural layer (Tedlar®) with an acrylic adhesive (DuPont 68080).
- the conventional laminate was composed of a printed PVF-based (Tedlar®) decorative layer bonded to a textured emboss resin layer (polyurethane-phenoxy resin, Bostik 10-669-3) overlying a pigmented PVF-based (Tedlar®) structural layer.
- PVDF-based decorative laminate of this invention outperforms conventional laminates in total heat release, peak heat release, and smoke emission testing.
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Claims (21)
- Stratifié flexible à base de polymère organique comprenant successivement :(a) une première couche comprenant un matériau à base de poly(fluorure de vinyle) ;(b) une seconde couche comprenant un matériau adhésif ; et(c) une troisième couche ayant une surface externe texturée, la couche comprenant un matériau à base de poly(fluorure de vinylidène).
- Stratifié selon la revendication 1, dans lequel le matériau à base de poly(fluorure de vinyle) est choisi dans le groupe constitué par des polymères, des copolymères, et des terpolymères de fluorure de vinyle.
- Stratifié selon la revendication 1 ou 2, dans lequel le matériau à base de poly(fluorure de vinylidène) est choisi dans le groupe constitué par des polymères, des copolymères, et des terpolymères de fluorure de vinylidène.
- Stratifié selon la revendication 1, 2 ou 3, dans lequel le matériau adhésif comprend un adhésif acrylique.
- Stratifié selon l'une quelconque des revendications 1 - 4, dans lequel la troisième couche est pigmentée.
- Stratifié selon l'une quelconque des revendications 1 - 5, dans lequel la troisième couche n'est pas endommagée par embossage.
- Stratifié selon l'une quelconque des revendications 1 - 6, ayant une valeur de rétention de texture d'au moins environ 70 % quand il est étiré de manière omnidirectionnelle à 150°C (300°F) en augmentant sa zone superficielle d'au moins environ 30 %.
- Stratifié selon l'une des revendications 1 - 7, comprenant en outre une couche imprimée recouvrant la troisième couche et une couche de couverture recouvrant la couche imprimée.
- Stratifié selon la revendication 8, dans lequel la couche imprimée est formée par un procédé choisi parmi des procédés par sérigraphie, transfert électrostatique, impression par jet d'encre, et héliogravure.
- Stratifié selon la revendication 8 ou 9, dans lequel la couche de couverture comprend un matériau à base de poly(fluorure de vinylidène).
- Stratifié flexible à base de polymère organique comprenant successivement :(a) une première couche comprenant un matériau à base de poly(fluorure de vinyle) ;(b) une seconde couche comprenant un matériau adhésif ;(c) une troisième couche comprenant une feuille métallique ;(d) une quatrième couche comprenant un matériau adhésif ; et(e) une cinquième couche ayant une surface externe texturée, la couche comprenant un matériau à base de poly(fluorure de vinylidène).
- Stratifié selon la revendication 11, dans lequel la couche de feuille métallique comprend une feuille d'aluminium.
- Stratifié selon la revendication 11 ou 12, comprenant en outre une couche imprimée recouvrant la cinquième couche et une couche de couverture recouvrant la couche imprimée.
- Stratifié selon l'une quelconque des revendications 1 - 13, comprenant en outre une couche adhésive pour fixer le stratifié à une substrat.
- Stratifié selon la revendication 14, dans lequel la couche adhésive est choisie parmi une couche adhésive activable par la chaleur et une couche adhésive sensible à la pression ;
- Panneau décoratif comprenant un stratifié flexible à base de polymère organique fixé à un substrat, dans lequel le stratifié comprend successivement :(a) une première couche comprenant une couche adhésive pour fixer le stratifié au substrat ;(b) une seconde couche comprenant un matériau à base de poly(fluorure de vinyle) ;(c) une troisième couche comprenant un matériau adhésif ; et(d) une quatrième couche ayant une surface externe texturée, la couche comprenant un matériau à base de poly(fluorure de vinylidène).
- Panneau décoratif selon la revendication 16, dans lequel le stratifié comprend en outre une couche imprimée recouvrant la quatrième couche et une couche de couverture recouvrant la couche imprimée.
- Panneau décoratif comprenant un stratifié flexible à base de polymère organique fixé à un substrat, dans lequel le stratifié comprend successivement :(a) une première couche comprenant une couche adhésive pour fixer le stratifié au substrat ;(b) une seconde couche comprenant un matériau à base de poly(fluorure de vinyle) ;(c) une troisième couche comprenant un matériau adhésif ;(d) une quatrième couche comprenant une feuille métallique ;(e) une cinquième couche comprenant un matériau adhésif ; et(f) une sixième couche ayant une surface externe texturée, la couche comprenant un matériau à base de poly(fluorure de vinylidène).
- Panneau décoratif selon la revendication 18, dans lequel le stratifié comprend en outre une couche imprimée recouvrant la sixième couche et une couche de couverture recouvrant la couche imprimée.
- Panneau décoratif ou stratifié selon l'une quelconque des revendications 1 - 19, dans lequel le substrat constitue une partie d'un intérieur d'avion.
- Panneau décoratif selon l'une quelconque des revendications1 - 20, dans lequel le stratifié est fixé de manière réversible au substrat.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US954209 | 1992-09-30 | ||
US08/954,209 US5976671A (en) | 1997-10-20 | 1997-10-20 | Polyvinylidene fluoride-based decorative laminate |
Publications (3)
Publication Number | Publication Date |
---|---|
EP0909635A2 EP0909635A2 (fr) | 1999-04-21 |
EP0909635A3 EP0909635A3 (fr) | 2000-07-05 |
EP0909635B1 true EP0909635B1 (fr) | 2004-06-02 |
Family
ID=25495092
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP19980203000 Revoked EP0909635B1 (fr) | 1997-10-20 | 1998-09-08 | Produit stratifié décoratif à base de poly(fluorore de vinylidène) |
Country Status (3)
Country | Link |
---|---|
US (1) | US5976671A (fr) |
EP (1) | EP0909635B1 (fr) |
DE (1) | DE69824252T2 (fr) |
Cited By (2)
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US7691470B2 (en) | 2001-03-05 | 2010-04-06 | 3Form | Laminate structure with polycarbonate sheets |
US8157942B1 (en) | 2007-05-08 | 2012-04-17 | Willham John E C | Multivariate color system with texture application |
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US6092915A (en) * | 1998-01-30 | 2000-07-25 | The Boeing Company | Decorative lighting laminate |
US6423167B1 (en) | 1998-06-05 | 2002-07-23 | Premark Rwp Holdings | Method for controlling laminate gloss |
US6632507B2 (en) | 1998-06-05 | 2003-10-14 | Premark Rwp Holdings, Inc. | Holographically enhanced decorative laminate |
US7682370B2 (en) * | 1998-08-20 | 2010-03-23 | Zimmer Spine, Inc. | Surgical tool for use in expanding a cannula |
CA2254415C (fr) * | 1998-11-18 | 2000-03-21 | Douglas F. Mantegna | Pellicule de lamination textile |
DE19858173A1 (de) * | 1998-12-16 | 2000-06-21 | Targor Gmbh | Schichtverbundmaterial auf der Basis von thermoplastischen Polymeren |
US6287672B1 (en) | 1999-03-12 | 2001-09-11 | Rexam, Inc. | Bright metallized film laminate |
US6506478B1 (en) | 2000-06-09 | 2003-01-14 | 3M Innovative Properties Company | Inkjet printable media |
US6555213B1 (en) | 2000-06-09 | 2003-04-29 | 3M Innovative Properties Company | Polypropylene card construction |
WO2001096098A1 (fr) | 2000-06-09 | 2001-12-20 | 3M Innovative Properties Company | Materiaux et procedes permettant de creer un support de reception de jet d'encre aqueux durable et etanche |
US7008700B1 (en) | 2001-03-05 | 2006-03-07 | 3-Form | Architectural laminate panel with embedded compressible objects and methods for making the same |
US7052761B2 (en) * | 2002-09-24 | 2006-05-30 | Schneller, Inc. | Dimensionally stable laminate with removable web carrier and method of manufacture |
US7070850B2 (en) * | 2002-12-31 | 2006-07-04 | 3M Innovative Properties Company | Drag reduction article and method of use |
WO2005068187A2 (fr) * | 2004-01-06 | 2005-07-28 | Avery Dennison Corporation | Lamines serigraphies textures |
US7939163B2 (en) * | 2004-05-03 | 2011-05-10 | Schneller Llc | Decorative laminate with graffiti resistance and improved combustion reaction properties |
US20060046017A1 (en) | 2004-09-01 | 2006-03-02 | 3Form | Architectural glass panels with embedded objects and methods for making the same |
US8071176B2 (en) | 2004-09-24 | 2011-12-06 | Arkema Inc. | Process for forming a weatherable polyvinyl chloride or polyolefin article |
US7452493B2 (en) * | 2005-04-15 | 2008-11-18 | The Boeing Company | Protective cover and tool splash for vehicle components |
US20070031645A1 (en) * | 2005-06-08 | 2007-02-08 | Wilde J C | Roll processed decorative laminate construction |
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CN101484511B (zh) * | 2006-06-29 | 2012-08-22 | 艾利丹尼森公司 | 聚偏1,1-二氟乙烯膜及其层压制件 |
US7824590B2 (en) * | 2007-09-25 | 2010-11-02 | The Boeing Company | Textured surfaces |
WO2010028352A1 (fr) * | 2008-09-08 | 2010-03-11 | Onboard Media Group, Llc | Procédé et dispositif pour réduire le dégagement de chaleur et la densité de fumée |
USD691289S1 (en) | 2012-09-05 | 2013-10-08 | 3Form, Inc. | Panel with cut and aligned thatch interlayer |
US10926520B2 (en) | 2015-02-27 | 2021-02-23 | The Boeing Company | Fire-resistant, gas permeable decorative laminate |
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US10751982B2 (en) | 2016-05-12 | 2020-08-25 | The Boeing Company | Methods and apparatus to remove gas and vapor from a panel for a decorative layer |
US10647099B2 (en) | 2016-05-12 | 2020-05-12 | The Boeing Company | Methods and apparatus to form venting channels on a panel for a decorative layer |
US10525685B2 (en) | 2016-05-12 | 2020-01-07 | The Boeing Company | Methods and apparatus to couple a decorative composite having a reinforcing layer to a panel |
US10661530B2 (en) | 2016-05-12 | 2020-05-26 | The Boeing Company | Methods and apparatus to couple a decorative layer to a panel via a high-bond adhesive layer |
US11130318B2 (en) * | 2016-05-12 | 2021-09-28 | The Boeing Company | Panels having barrier layers and related methods |
JP2019150976A (ja) * | 2018-03-01 | 2019-09-12 | パナソニックIpマネジメント株式会社 | 加飾金属部品の加工方法と加飾金属部品 |
US11034428B2 (en) | 2018-08-10 | 2021-06-15 | The Boeing Compny | Anti-microbial decorative laminate |
US11222284B2 (en) | 2019-06-10 | 2022-01-11 | The Boeing Company | Laminate nonconformance management system |
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US3616192A (en) * | 1970-02-04 | 1971-10-26 | Riegel Paper Corp | Decorative polyvinyl fluoride laminations |
US3869326A (en) * | 1971-08-18 | 1975-03-04 | William A Matzke | Textured film finished panels and method therefor |
US4465728A (en) * | 1972-09-25 | 1984-08-14 | H.L.H. Corp. | Dye decorated plastic articles |
US3946137A (en) * | 1973-05-16 | 1976-03-23 | Formica Corporation | Machineable decorative laminates |
US4068034A (en) * | 1974-02-12 | 1978-01-10 | Kureha Kagaku Kogyo Kabushiki Kaisha | Heat-insulation laminate of polyvinylidene fluoride, metal and plastic |
US4693926A (en) * | 1984-08-31 | 1987-09-15 | The Boeing Company | Flexible, fire-resistant, decorative laminates and methods of manufacture thereof |
EP0173795B1 (fr) * | 1984-08-31 | 1990-06-06 | The Boeing Company | Laminés décoratifs, ininflammables, flexibles, et méthodes de fabrication de ceux-ci |
US5085921A (en) * | 1987-04-20 | 1992-02-04 | The Boeing Company | Decorative laminates with heat release reducing and ink discoloration preventive protective layer |
US4788091A (en) * | 1987-08-17 | 1988-11-29 | Emhart Enterprises Corp. | Flame retardant embossing film |
US4988540A (en) * | 1988-05-25 | 1991-01-29 | E. I. Du Pont De Nemours And Company | Method of making fluoropolymer laminates |
US4877683A (en) * | 1988-05-25 | 1989-10-31 | E. I. Du Pont De Nemours And Company | Fluoropolymer laminates |
US5203941A (en) * | 1989-10-19 | 1993-04-20 | Avery Dennison Corporation | Process for manufacturing plastic siding panels with outdoor weatherable embossed surfaces |
US5238725A (en) * | 1990-12-21 | 1993-08-24 | E. I. Du Pont De Nemours And Company | Method for forming a structural panel with decorative facing and product thereof |
CA2084716C (fr) * | 1992-11-05 | 1999-11-16 | John R. Johnson | Stratifie exterieur d'automobile muni d'un adhesif autocollant |
-
1997
- 1997-10-20 US US08/954,209 patent/US5976671A/en not_active Expired - Lifetime
-
1998
- 1998-09-08 DE DE1998624252 patent/DE69824252T2/de not_active Expired - Lifetime
- 1998-09-08 EP EP19980203000 patent/EP0909635B1/fr not_active Revoked
Cited By (6)
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US7691470B2 (en) | 2001-03-05 | 2010-04-06 | 3Form | Laminate structure with polycarbonate sheets |
US8157942B1 (en) | 2007-05-08 | 2012-04-17 | Willham John E C | Multivariate color system with texture application |
US8182903B2 (en) | 2007-05-08 | 2012-05-22 | 3Form, Inc. | Multivariate color system with texture application |
US8268106B2 (en) | 2007-05-08 | 2012-09-18 | 3Form, Inc. | Multivariate color system with texture application |
US8617695B2 (en) | 2007-05-08 | 2013-12-31 | 3Form, Inc. | Multivariate color system with texture application |
US9348065B2 (en) | 2007-05-08 | 2016-05-24 | 3Form, Llc | Multivariate color system with texture application |
Also Published As
Publication number | Publication date |
---|---|
US5976671A (en) | 1999-11-02 |
EP0909635A3 (fr) | 2000-07-05 |
EP0909635A2 (fr) | 1999-04-21 |
DE69824252D1 (de) | 2004-07-08 |
DE69824252T2 (de) | 2005-06-23 |
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